Subpart N Materials Handling

Trainer Objectives Describe the requirements for secure storage of materials. Explain the requirements for operating powered industrial trucks. Indicate the requirements for operation of overhead and gantry cranes.

Subpart N - Materials Handling & Storage (1910.176 - 184) Powered Industrial Trucks – Operator training Powered Industrial Trucks – Safe operating condition Secure storage Standard: 1910. Powered Industrial Trucks – Operator certification Powered Industrial Trucks – Examination

1910.176(a) Use of mechanical equipment Where mechanical handling equipment is used, sufficient safe clearances shall be allowed for aisles, at loading docks, through doorways and wherever turns or passage must be made

1910.176(a) Use of mechanical equipment Aisles and passageways shall be kept clear and in good repair, with no obstruction across or in aisles that could create a hazard Permanent aisles and passageways shall be appropriately marked Stored material creating a hazard across the aisle

1910.176(b) Secure storage Storage of material shall not create a hazard Bags, containers, etc.., stacked, blocked, interlocked and limited in height so that they are stable and secure against sliding or collapse Material is not stable

1910.176(c) Housekeeping Storage areas shall be kept free from accumulation of materials that constitute hazards from tripping, fire, explosion, or pest harborage (e) Clearance limits: Signs to warn of clearance limits shall be provided

1910.176 (g) Guards Covers and/or guard- rails shall be provided to protect personnel from the hazards of open pits, tanks, vats, ditches, etc..

1910.177 Servicing multi-piece and single piece rim wheels (a)(1) Applies to the servicing of multi-piece and single piece rim wheels used on large vehicles such as trucks, tractors, trailers, buses and off-road machines

1910.177(c) Training (1)(i) The employer shall assure that no employee services any rim wheel unless the employee has been trained and instructed in Correct procedures of servicing the type of wheel being serviced, and In the safe operating procedures described in paragraphs (f) and (g) of this section

02/27/1997 - Evaluation of an employee's ability to perform servicing of multi-piece or single piece rim wheels The §1910.177 standard does not specify the details of training, but simply requires the development and maintenance of employee proficiency in servicing. A mechanic's level of proficiency must be established by demonstration of his or her familiarity with and ability to use the §1910.177 standard and the charts and rim manual.

1910.178 Powered industrial trucks General Requirements (1) Contains safety requirements relating to: Fire protection, Design, Maintenance, and Use of fork trucks, tractors, platform lift trucks, motorized hand trucks, and other specialized industrial trucks powered by electric motors or internal combustion engines

1910.178 Powered industrial trucks (2) Design and construction requirements for powered industrial trucks established in the "American National Standard for Powered Industrial Trucks, Part II, ANSI B56.1-1969” (3) Approved trucks shall bear a label or some other identifying mark indicating approval by a nationally recognized testing laboratory

1910.178 Powered industrial trucks (4) Modifications and additions which affect capacity and safe operation shall not be performed by the customer or user without manufacturers prior written approval

1910.178 Powered industrial trucks (6) All nameplates and markings are in place and are maintained in a legible condition

1910.178 (e) Powered industrial trucks Safety Guards (1) High Lift Rider trucks shall be fitted with an overhead guard…unless operations do not permit… (2) If the type of load presents a hazard, the user shall equip fork trucks with a vertical load backrest extension

1910.178(f) Fuel Handling and Storage (1)The storage and handling of liquid fuels such as gasoline and diesel fuel shall be in accordance with NFPA Flammable and Combustible Liquids Code (NFPA No. 30-1969) (2)The storage and handling of liquefied petroleum gas fuel shall be in accordance with NFPA Storage and Handling of Liquefied Petroleum Gases (NFPA No. 58-1969)

1910.178(g) Changing and charging storage batteries (1)Battery charging installations shall be located in areas designated for that purpose (2)Facilities provided for Flushing and neutralizing spilled electrolyte, For fire protection, Protecting charger from damage by trucks, For adequate ventilation for dispersal of fumes

03/08/2002 - Clarification of PIT requirements covering: LP-gas storage, and eye wash stations. Must LP cylinders used for internal combustion forklifts be stored outside only, or is it permissible to store them inside a warehouse or industrial building? : §1910.178(f)(2) incorporating by reference, the NFPA 58-1969, Storage and Handling of Liquified Petroleum Gases.

NFPA Storage within buildings not frequented by public (such as industrial buildings) Maximum = 735lbs water capacity 300 lbs LP-Gas capacity Storage in special rooms or buildings Maximum = 10,000 lbs

03/08/2002 - Clarification of PIT requirements covering: eye wash stations. What regulations state how close eyewash station must be to a battery changing/charging station? Because §1910.178 does not have a specific requirement for eyewash facilities, the general standard at §1910.151 applies. When necessary, facilities for drenching or flushing the eyes “shall be provided within the work area for immediate emergency use.”

03/08/2002 - Clarification of PIT requirements covering: and eye wash stations. OSHA would consider the guidelines set by such sources (ANSI) Z358.1-1998, Emergency Eyewash and Shower Equipment, which states, at section 7.4.4, that eyewash facilities are to be located to require no more than 10 seconds to reach but that where a strong acid or caustic is used, the unit should be immediately adjacent to the hazard.

1910.178(g) Changing and charging storage batteries (4)A conveyor, overhead hoist, or equivalent material handling equipment shall be provided for handling batteries

1910.178(g) Changing and charging storage batteries (5)Reinstalled batteries shall be properly positioned and secured in the truck

1910.178(g) Changing and charging storage batteries (7)When charging batteries, pour acid into water; not water poured into acid (8)Trucks properly positioned and brake applied before attempting to change or charge batteries (9)Care taken to assure that vent caps are functioning

1910.178(g) Changing and charging storage batteries (10)Smoking shall be prohibited in the charging area (11)Precautions shall be taken to prevent open flames, sparks, or electric arcs in battery charging areas DANGER No smoking sparks or open flames (12) Tools and metallic objects shall be kept away from the tops of batteries

1910.178(h) Lighting for operating areas Where general lighting is less than 2 lumens per square foot, auxiliary directional lighting shall be provided on the truck

1910.178(k) Trucks and railroad cars Truck brakes set and wheel chocks placed under the rear wheels to prevent rolling while they are boarded with powered industrial trucks Wheel stops or other recognized positive protection shall be provided to prevent railroad cars from moving during loading or unloading operations

1910.178(l) Operator training (1)Ensure each PIT operator is competent to operate a powered industrial truck safely Prior to operating a powered industrial truck the employer shall ensure that each operator has successfully completed the training required Required: Lecture Practical training Evaluation

1910.178(l) Operator training (2)(i)Trainees operate a PIT only: (A)Under the direct supervision of persons who have the knowledge, training, and experience to train operators and evaluate their competence (B)Where such operation does not endanger the trainee or other employees.

1910.178(l) Operator training (2)(ii)Training shall consist of a combination of: Formal instruction (e.g., lecture, discussion, interactive computer learning, video tape, written material), Practical training (demonstrations performed by the trainer and practical exercises performed by the trainee), and Evaluation of the operator's performance in the workplace.

1910.178(l) Operator training (2)(iii) All operator training and evaluation shall be conducted by persons who have the knowledge, training, and experience to train powered industrial truck operators and evaluate their competence.

1910.178(l) Operator training (3)Training topics: Operating instructions, warnings, and precautions; Differences between the truck and the automobile; Truck controls and instrumentation: where they are located, what they do, and how they work; Engine or motor operation; Steering and maneuvering; Fork and attachment adaptation;

1910.178(l) Operator training Training topics (contd.): Vehicle capacity; Vehicle stability; Any vehicle inspection and maintenance that the operator will be required to perform; Refueling and/or charging of batteries; Operating limitations; operating instructions, warnings, or precautions listed in the operator's manual

1910.178(l)(3)(ii) Workplace-related topics: Surface conditions where the vehicle will operate Composition of load, and load stability Load manipulation, stacking, and unstacking; Pedestrian traffic Ramps and other sloped surfaces that could affect the vehicle's stability;

1910.178(l) Certification (6)The certification shall include: The name of the operator; The date of the training; The date of the evaluation, and; The identity of the person(s) performing the training or evaluation PIT Training & Evaluation

1910.178(m) Truck operations (1)Trucks never driven up to anyone standing in front of a bench or other fixed object (2)No one allowed to stand or pass under the elevated portion of any truck, (3)Unauthorized personnel not permitted to ride on powered industrial trucks

1910.178(m) Truck operations (4)Prohibit arms or legs from being placed between the uprights of the mast or outside the running lines of the truck (5)(i)Truck left unattended, load engaging means fully lowered, controls neutralized, power shall be shut off, and brakes set 25 ft. or more away from the vehicle which remains in his view

1910.178(m) Truck operations (6)A safe distance shall be maintained from the edge of ramps or platforms while on any elevated dock, or platform or freight car. Trucks shall not be used for opening or closing freight doors. (7)The flooring of trucks, trailers, and railroad cars shall be checked for breaks and weakness before they are driven onto.

1910.178(m) Truck operations (9)An overhead guard shall be used as protection against falling objects. It should be noted that an overhead guard is intended to offer protection from the impact of small packages, boxes, bagged material, etc.,

1910.178(m) Truck operations (12)(i)Use of a safety platform firmly secured to the lifting carriage and/or forks (ii)Means shall be provided whereby personnel on the platform can shut off power to the truck

1910.178(n) Traveling (1)All traffic regulations shall be observed, A safe distance shall be maintained approximately three truck lengths from the truck ahead, and; Three truck lengths minimum

1910.178(n) Traveling (4)Driver required to slow down and sound horn at cross aisles and other locations where vision is obstructed (4)If the load being carried obstructs forward view, driver shall travel with the load trailing

1910.178(n) Traveling Traveling on grades, loaded trucks driven with the load upgrade When traveling, load and load engaging means tilted back if applicable, and raised only as far as necessary to clear the road surface

1910.178(n) Traveling (11)Dockboard or bridgeplates, shall be properly secured (11)Dockboard or bridgeplates shall be driven over carefully and slowly and their rated capacity never exceeded.

1910.179(b) Overhead and gantry cranes General requirements: (1)Applies to overhead and gantry cranes, including: semigantry, cantilever gantry, wall cranes, storage bridge cranes, and others having the same fundamental characteristics These cranes are grouped because they all have trolleys and similar travel characteristics

Clarification of OSHA standard on Overhead and Gantry Cranes Does this standard apply to underhung cranes, hoists, and monorails? This standard does not apply to underhung cranes, overhead hoists, or monorails. Underhung cranes and monorails are covered in ANSI B30.11-1980, a National Consensus Standard.

1910.179 (b) Overhead and gantry cranes (2)All new overhead and gantry cranes constructed and installed on or after August 31, 1971, shall meet the design specifications of the American National Standard Safety Code for Overhead and Gantry Cranes, ANSI B30.2.0-1967

1910.179 (b) Overhead and gantry cranes The rated load of the crane plainly marked on each side of the crane, and if the crane has more than one hoisting unit, each hoist shall have its rated load marked on it or its load block and this marking clearly legible from the floor

1910.179 (b) Overhead and gantry cranes Only designated personnel shall be permitted to operate a crane

Training for travel lift (mobile gantry crane) operators OSHA requires that only designated personnel be permitted to operate a crane. OSHA defines designated at 1910.179(a)(35) as: Selected or assigned by the employer or the employer's representative as being qualified to perform specific duties OSHA would interpret "qualified" in light of operator- qualifications provisions of industry standards such as ANSI B30.2.

1910.179 (c) Cabs (2) Access to the cab and/or bridge walkway shall be by a conveniently placed fixed ladder, stairs, or platform requiring no step over any gap exceeding 12 inches. (2)Fixed ladders shall be in conformance with the American National Standard Safety Code for Fixed Ladders

1910.179 (e)(1) Trolley Stops (i)Stops shall be provided at the limits of travel of the trolley. (iii)Minimum height of the trolley stop at least 1/2 the diameter of the trolley wheel Min. 1/2 diameter of trolley wheel Trolley stop

1910.179 (e)(4) Rail Sweeps Bridge trucks shall be equipped with sweeps which extend below the top of the rail and project in front of the truck wheels

1910.179 (e)(6) Guards for moving parts (i)Exposed moving parts shall be guarded; such as: Gears, Set screws, Projecting keys, Chains & chain sprockets, and Reciprocating components which might constitute a hazard under normal operating conditions

1910.179 (g) Electric equipment For floor-operated cranes, the controller or controllers if rope operated, shall automatically return to the "off" position when released by the operator (5)Power supply to runway conductors capable of being locked out

1910.179 (h) Hoisting Equipment Sheave grooves shall be smooth and free from surface defects which could cause rope damage.

1910.179(j) Inspections Frequent inspection - Daily to monthly intervals: including observation during operation Periodic inspection - 1 to 12-month intervals Daily - All functional operating mechanisms for maladjustment interfering with proper operation. Daily - Deterioration or leakage in lines, tanks, valves, drain pumps, and other parts of air or hydraulic systems.

1910.179(j) Inspections Hooks with deformation or cracks. Visual inspection daily; Monthly inspection with a certification record which includes the: Date of inspection, The signature of the person who performed the inspection and The serial number, or other identifier, of the hook inspected

1910.179(j) Inspections All functional operating mechanisms for excessive wear of components Rope reeving for noncompliance with manufacturer's recommendations

1910.179(j) Inspections Periodic inspections: Deformed, cracked, or corroded members Cracked or worn sheaves and drums Worn, cracked or distorted pins, bearings, shafts, gears, rollers, locking and clamping devices Excessive wear on brake system parts Loose bolts or rivets

1910.179(n) Handling the load The crane shall not be loaded beyond its rated load The load shall be well secured and balanced before it is lifted Hoist rope shall not be kinked No sudden acceleration or deceleration of the moving load Cranes not be used for side pulls unless authorized

1910.179(n)(4) Limit switches At the beginning of shift, the upper limit switch of hoist shall be tried out under no load Extreme care shall be exercised; the block shall be "inched" into the limit or run in at slow speed If switch does not operate properly, the appointed person shall be notified

1910.184 Slings Safe operating practices for all slings: (1)Damaged or defective slings shall not be used (2)Slings shall not be shortened with knots or bolts (3)Sling legs shall not be kinked (4)Not be loaded in excess of their rated capacities (5)Used in a basket hitch shall have the loads balanced to prevent slippage (6)Securely attached to their loads

1910.184 Slings Safe operating practices for all slings: (7)Slings shall be padded or protected from sharp edges (8)Suspended loads shall be kept clear of all obstructions (9)All employees shall be kept clear of suspended loads and new lifts (10)Hands or fingers shall not be placed between the sling and its load while the sling is being tightened around the load

1910.184(d) Inspections Each day before use, slings, fastenings and attachments inspected for damage or defects by a competent person designated by the employer Additional inspections performed during sling use, where service conditions warrant

1910.184(f) Wire rope slings Wire rope slings immediately removed from service if any following conditions are present: Ten randomly distributed broken wires in one rope lay, or five broken wires in one strand in one rope lay Wear or scraping of one-third the original diameter of outside individual wires Kinking, crushing, bird caging or any other damage resulting in distortion of the wire rope structure Evidence of heat damage

1910.184(f) Wire rope slings 10° max Wire rope slings removed from service if any of the following conditions are present: End attachments that are cracked, deformed or worn Hooks opened more than 15 percent of the normal throat opening, or twisted more than 10 degrees from the plane of the unbent hook